Reinforced floors for modular bathrooms

ABSTRACT

Reinforced floor components of prefabricated bathroom pods. The floor components are reinforced and integrated into bathroom pods or other building units in such a manner as to add significant strength to the bathroom pods to resist bending, twisting and sagging, and/or to aid in lifting and supporting the weight of the bathroom pods, and thereby add to the structural integrity of the prefabricated bathroom pods to which they are attached.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.17/483,189, filed Sep. 23, 2021, the entirety of which is incorporatedherein by reference.

TECHNICAL FIELD

The present invention relates generally to showers, bathroom floors andother drainable structures that are part of a prefabricated bathroom podconstruction or other similar types of modular building units, and moreparticularly to pod bathroom floors where the pod bathroom floor isreinforced and integrated into the bathroom pod or other building unitin such a manner as to add significant strength to the bathroom pod toresist bending, twisting and sagging, and/or to aid in lifting andsupporting the weight of the bathroom pod floors and walls.

BACKGROUND

Most bathroom shower enclosures are created using complicatedconstruction methods. For example, using conventional techniques, askilled installer frames out the area to be enclosed using two-by-fourwooden, steel or aluminum studs to create a shower enclosure space. Feltor tar paper is then laid over a subfloor area enclosed within thespace. A flexible, leak-proof liner is installed on top of the felt ortar paper and attached to the frame. Next, the installer attaches drywall boards to the framing studs, creating shower sidewalls. A hole iscut in the liner to allow for a drain, and a layer of mortar is appliedto the shower sidewalls and curb and allowed to cure. Additional mortaris applied on top of the leak-proof liner and hand-shaped to form ashower floor which slopes toward the drain such that water from theshower flows toward the drain. After the mortar has cured, shower tileis applied to the floor and sidewalls to create the finished enclosure.

The process of creating an enclosed shower in this manner istime-consuming and requires experience, knowledge and skill in order tomaintain the proper pitch and uniformity in shaping the floor.Irregularities in the pitch of the floor can cause water from the showernot to drain properly or make tiling the shower enclosure difficult. Theliners are also susceptible to punctures or leaks and may be difficultfor the installer to properly form square corners at the intersection ofthe shower sidewalls and floor. Additionally, the mortar layer used tocreate the floor is necessarily thick in order to form a sloped surface,therefore the time required for the floor to cure before applying tilemay be quite long (e.g., greater than 24 hours). As a result,construction projects that require a multitude of showers or bathroomsto be fabricated such as residential complexes, hotels, and hospitalswill be more expensive and take longer due to the required labor.

In recent years, to decrease this cost especially for the aforementionedcommercial applications, the process of shower installation has beenvastly improved by the introduction of prefabricated shower bases usedfor forming the shower floor. Use of these prefabricated shower basessignificantly decreases the amount of time and skill required toconstruct a bathroom shower enclosure, as well as providing more of aconsistent and reliable flooring surface upon which to apply floorcoverings. These shower bases are pre-constructed molded units having asloping floor, an integrated drain, curb, sidewalls, and a horizontalsurface on the top of each sidewall for receiving drywall such that thedrywall surface is substantially flush to the shower base sidewalls.Installation of the shower base involves securing a section of drainpipe to the drain, applying adhesive and sealing material to the subfloor where the base will rest, and seating the base on the subfloor.Tile can then be applied directly to the shower walls and shower basewithout the need for first applying mortar.

Other improvements in the construction process have included theprovision of entire prefabricated bathroom pods, that are assembledoff-site and installed in a building under construction to decrease thecost of labor when building suites in the aforementioned commercialapplications.

However, more than just prefabricated shower components are needed tocreate prefabricated bathroom pods. In particular, there exists a needto make the entire bathroom floor a monolithic and fortified componentof such pods that are sturdy enough to withstand the weight and forcesexerted on the bathroom floor and other pod components duringfabrication, lifting, transport and installation, without fear of damageoccurring to the bathroom floor or another part of the prefabricatedbathroom pod.

Bathroom pod construction is a new and growing competitive constructionsegment which has certain advantages over conventional constructionmethods, particularly in large new built projects. Bathroom podmanufacturers have been successful in eliminating many deficienciesassociated with traditional bathroom construction methods undertaken inthe field on a construction site by having pod company employeesresponsible for all or substantially all of the construction andassembly of a pod in a factory setting. When the bathroom pod isfinished, it is shipped to a construction site where it is lifted andthen installed in the structure as a finished bathroom.

The factory environment allows significantly more oversight and controlover how and when a pod is manufactured, including sequencing differentgroups of pod employees based upon when their trade expertise isrequired. Pod supervisors are also readily available to oversee realtime work quality, sequencing and scheduling.

With all employees working for the pod manufacturer, the pod employeesavoid many of the friction occurring on a traditional construction sitebetween and among different trades present in traditional construction,including, among other things, one trade intentionally or recklesslynegatively impacting finished work of another trade.

Bathroom pod manufacturers have introduced meaningful innovation in theconstruction of bathrooms. However, that innovation has not, for themost part, trickled down to the construction of pod bathroom floorcomponents. Currently, portions of the pod bathroom floor are stillbeing manufactured in much the same way that bathroom floors have beenmanufactured for years in conventional construction. Bathroom pods arestill installed with basic substrates on which pod floors are assembledand installed using a series of off-the-shelf bathroom products whichbasically mimics traditional (i.e., non-modular) construction practices.Consequently, pod bathroom floors share many of the same headaches anddrawbacks associated with traditional construction, along with severaladditional meaningful drawbacks that are uniquely attributable to podconstruction. For example, since pods are manufactured in a factory,they must be shipped from the factory to the construction site and thenplaced on substrates in buildings with any number of stories.Heretofore, the interconnections between bathroom pod floors and thewalls of the pod have not employed independent weight bearing substratesor anti-torsional features which prevent pod floors and/or walls fromtwisting, bending, sagging and/or otherwise potentially compromising theinstalled floor and wall coverings, causing them to loosen or dislodgefrom the pod floor and/or walls when the completed pod is installed on atraditional construction site substrate.

SUMMARY

With the introduction of the herein disclosed new reinforced podbathroom floor systems, the bathroom pod industry will now have aone-piece pod flooring system which will revolutionize how the bathroompod industry manufactures bathroom pod floors. Most importantly, theone-piece pod bathroom floor systems provide a full menu of customsolutions for the bathroom pod industry which are not otherwiseavailable and will save significant time and cost. The inventions setforth in this application address many of the thorny issues currentlyplaguing the bathroom pod manufacturers related to the bathroom podcomponent. Specifically, the pod bathroom floor component describedherein not only provides one or more bathroom shower floors, it alsoprovides all the other bathroom floor structures which include but arenot limited to one or more flat bathroom areas, one or more non-showerpitched bathroom wet areas, one or more dry pitched bathroom areas, theentrance to the bathroom, along with any custom size bathroom floorcomponent required, while also having the pod bathroom floor entrancecomponent fit into a shallow substrate slab recess (for example, 1.5″),thereby avoiding the excessive costs of recessing the slab even more.Most importantly, all of the above is contained in a one-piece bathroomfloor component, which has adequate independent weight bearing floorcapabilities as well as being resistant to sagging, bending, twistingand other deformations, and in some embodiments also has pod wall weightbearing capabilities, so the bathroom pod manufacturer can order andreceive a one piece pod bathroom floor component which can be assembledwith the pod wall panels in a very short period of time (e.g., less than45 minutes).

A prefabricated bathroom pod according to an embodiment of the presentdisclosure may comprise a plurality of wall studs supporting wallpanels, a ceiling structure, electrical wiring, plumbing (as well asassociated accessories), and a bathroom floor component including one ormore plastic and/or foam members, the bathroom floor component beingcharacterized as being encapsulated in a waterproof covering ormembrane. The walls may connect the ceiling to the bathroom floorcomponent, the electrical wiring may be attached to at least one of theplurality of walls and/or the ceiling, and the plumbing may be attachedto at least one of the plurality of walls and/or the bathroom floorcomponent. Thereafter, wall coverings and floor coverings may be appliedto the bathroom pod walls and floor.

A prefabricated bathroom pod according to another embodiment of thepresent disclosure may comprise a plurality of wall studs supportingwall panels, a ceiling structure, electrical wiring, plumbing (as wellas associated accessories, if any), and a bathroom floor componentincluding at least a first elongated frame member that is adhered to oneor more plastic or foam floor members, the bathroom floor componentbeing characterized as being either encapsulated in a waterproofcovering or membrane or comprising one or more closed cell floor panelswhich are not encapsulated in a waterproof covering. The walls mayconnect the ceiling to the bathroom floor component, the electricalwiring may be attached to at least one of the plurality of walls and/orthe ceiling, and the plumbing may be attached to at least one of theplurality of walls and/or the bathroom floor component. Thereafter, wallcoverings and floor coverings may be applied to the bathroom pod wallsand floor.

A bathroom floor component according to an embodiment of the presentdisclosure may comprise one or more floor edge strengthening peripheralmembers, one or more cross-brace transverse floor strengthening members,and one or more plastic and/or foam members. The one or more edge floorstrengthening peripheral members may be joined to the one or morecross-brace transverse floor strengthening members, defining one or morepockets, and at least one of the plurality of foam and plastic materialsmembers may be disposed in each of the one or more pockets.

A method of fabricating and using a bathroom floor component accordingto an embodiment of the present disclosure may comprise positioning oneor more foam and/or plastic members that are spaced apart from eachother, creating a peripheral framework that may include a plurality offloor edge strengthening members forming an enclosed perimeter aroundall of the one or more foam and/or plastic floor members, providing aplurality of cross-brace transverse floor strengthening members betweenthe two or more foam and/or plastic floor members, and attaching each ofthe one or more foam and/or plastic floor members to at least one of theplurality of edge peripheral members, and/or to at least one of theplurality of cross-brace transverse strengthening members.

A prefabricated bathroom pod according to another embodiment of thepresent disclosure may comprise a ceiling, a floor component, aplurality of walls, electrical wiring and plumbing accessories. Animprovement for such a bathroom pod may comprise a bathroom floorcomponent including a perimeter raised platform strengthening member,which defines one or more of a planar upper surface and planar lowersurface, defining an outer perimeter of the bathroom floor component,and a foam and/or plastic floor member surrounded by the perimeterperipheral member. The foam and/or plastic floor member may define adrain aperture, and at least a first top surface all or a portion ofwhich is sloped toward the drain aperture. The foam and/or plastic floormember may be a single monolithic member or may be comprised of aplurality of separate floor members, which may or may not be separatedby, and attached to, one or more cross-brace transverse strengtheningmembers. In embodiments, the perimeter raised platform strengtheningmember may be adapted to strengthen the floor component and attach toand support the plurality of bathroom pod walls.

In embodiments, an improvement to this arrangement may include one ormore of a rectangular wall frame member and a U-shaped channel forming alower edge of the bathroom walls, with both the U-shaped channel and therectangular shaped frame member sized and shaped to mate with the planarupper surface of the raised platform strengthening member, and one ormore fasteners adapted to pass through the raised platform strengtheningmember and one or more of the U-shaped channel and the wall frame memberto connect the floor component to the walls of the pod. The raisedplatform can be substantially the same width as the wall studs 110, orsubstantially the same width as the wall studs 110 with shower boardattached to it, or narrower or wider than both of these two widths,based on the customer needs or other design criteria.

In other embodiments, an improvement to this arrangement may include oneor more of a rectangular wall frame member and a U-shaped channelforming a lower edge of the bathroom walls, with both the U-shapedchannel and the rectangular shaped frame member sized and shaped to matewith the planar upper surface of the raised platform strengtheningmember, where wallboard (e.g., sheet rock) is associated with the podwalls, the width of the planar upper surface of the raised platformstrengthening member being at least as wide as the combined widths ofthe wallboard and the U-shaped channel or the rectangular shaped framemember, and further comprising one or more fasteners adapted to passthrough the raised platform strengthening member and one or more of theU-shaped channel and the wall frame member to connect the floorcomponent to the walls of the pod.

In still other embodiments, an improvement to this arrangement mayinclude one or more transverse bars, straps or metal frames associatedwith the bottom side of the bathroom floor component. The transversebars, straps or metal frame may define one or more apertures adapted toalign with corresponding apertures defined by said perimeter raisedplatform strengthening member, said one or more fasteners adapted topass through the apertures in the strengthening bars/straps/metal frame,said raised platform strengthening member and the one or more of theU-shaped channel and the wall frame member to connect the floorcomponent to the walls of the pod.

A bathroom floor component according to another embodiment of thepresent disclosure may comprise one or more foam and/or plastic floormembers, a raised platform strengthening member including a top planarsurface, the raised platform strengthening member at least partiallysurrounding the one or more foam and/or plastic floor members, an outerwall of the raised platform strengthening member defining an outerperimeter of the bathroom floor component, the raised platformstrengthening member also defining an inner wall and a bottom surface. Astrengthening border member may be disposed between the one or more foamand/or plastic floor members and the raised platform strengtheningmember. The one or more foam and/or plastic floor members may define adrain aperture and include at least a first top surface all or a portionof which slopes toward the drain aperture.

In embodiments, the raised platform strengthening member is reinforcedby weight-bearing, anti-compression elements. In embodiments, the floorpanels may consist of a single, closed cell panel as the only floorpanel for the bathroom floor component. In embodiments, such singleclosed cell panel may also be the only panel used with a raised pod wallsupport platform.

A method of fabricating and using a bathroom floor component accordingto yet another embodiment of the present disclosure may comprisemachining a foam and/or plastic floor member having at least one slopedsurface extending downwardly toward a drain aperture, further machiningfrom the same piece of foam and/or plastic a raised platformstrengthening member at least partially surrounding the floor member,the raised platform strengthening member adapted to be placed inregistry with the pod walls to at least partially support the weight ofthe pod walls. The raised platform strengthening member may be providedwith apertures suited to receiving fasteners to connect the bathroomfloor component to lower ends of the pod walls. The method offabricating in this embodiment comprises encapsulating the entirety ofthe bathroom floor component in a waterproof layer.

A method of fabricating and using a bathroom floor component accordingto another embodiment of the present disclosure may comprise machining afoam and/or plastic floor member having at least one sloped surfaceextending downwardly toward a drain aperture, further machining from thesame piece of foam and/or plastic a raised platform strengthening memberat least partially surrounding the floor member, the raised platformstrengthening member adapted to be placed in registry with the pod wallsto at least partially support the weight of the pod walls, machiningvoids in the raised platform strengthening member adapted to receiveanti-compression elements which will serve to support some or all of theweight of the pod walls, and associating the anti-compression elementswith the voids. The raised platform strengthening member and/or theanti-compression elements may be provided with apertures suited toreceiving fasteners to connect the bathroom floor component to lowerends of the pod walls. The method of fabricating in this embodimentcomprises encapsulating the entirety of the bathroom floor component ina waterproof layer.

A method of fabricating and using a bathroom floor component accordingto a still further embodiment of the present disclosure may comprisemachining one or more plastic and/or foam floor members with a contour,providing one or more transverse strengthening members and one or moreperipheral strengthening members, associating the foam and/or plasticfloor members with the one or more transverse strengthening members andthe one or more peripheral strengthening members, and attaching the foamand/or plastic floor members to the one or more transverse strengtheningmembers and the one or more peripheral strengthening members.

A method of fabricating and using a bathroom floor component accordingto another embodiment of the present disclosure may comprise machiningone or more foam and/or plastic floor members, providing one or moretransverse strengthening members, associating the foam and/or plasticfloor members with the one or more transverse strengthening members, andattaching the foam and/or plastic floor members to the one or moretransverse strengthening members.

A still further method comprises providing a raised peripheral supportplatform around at least a portion of a periphery of the two or morefoam and/or plastic floor members.

In some embodiments, an even further method comprises the provision of areinforcing member such as a metal frame associated with, and supportingan underside of, the raised peripheral support platform and/or theunderside of one or more portions of floor of the bathroom floorcomponent.

In embodiments, the bathroom floor component is encapsulated in awaterproof shell on some or all sides, which adds to the strength andwater imperviousness thereof.

A prefabricated bathroom pod according to another embodiment of thepresent disclosure may comprise a ceiling, a plurality of walls, andelectrical wiring and plumbing accessories, as well as a bathroom floorcomponent supported by a support substrate. In one embodiment, the floorcomponent that is supported by the substrate is encapsulated in awaterproof shell. In another embodiment, the floor component and aportion or all of the substrate are both encapsulated in a waterproofshell. In a third embodiment, the floor component, the floor substrateand a raised peripheral platform are all encapsulated in a waterproofshell. In a forth embodiment, the floor component includes a supportframe, where one or more portions of the support frame may beencapsulated in a waterproof shell and/or one or more portions may notbe so encapsulated.

In still further embodiments, a bathroom floor component ofprefabricated bathroom pod may be comprised of a single bathroom floorpanel which is made of a material that is impervious to water, such asclosed cell foam or polyethylene. In such embodiments, a single closedcell floor panel could be used for the bathroom floor, which would notnecessarily need to be encapsulated in a waterproof shell, althoughencapsulating the floor component in a waterproof shell could optionallybe done.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a bottom exploded perspective view of a bathroom podconstructed with a prefabricated bathroom floor component according to afirst embodiment of the present disclosure.

FIG. 2A is a top perspective assembled view of the bathroom pod of FIG.1 constructed with a prefabricated bathroom floor component of FIG. 4A.

FIG. 2B is an enlargement of the area of detail shown in FIG. 2A,showing a corner of the prefabricated bathroom floor component fastenedto the walls of the bathroom pod.

FIG. 2C is a front elevational sectional view of the bathroom pod ofFIG. 2A, taken along lines 2C-2C thereof.

FIG. 2D is a side elevational sectional view of the bathroom pod of FIG.2A, taken along lines 2D-2D thereof.

FIG. 3A is an enlargement of the area of detail shown in FIG. 2C,showing internal details of the fastened connection of the prefabricatedfloor component to the walls of the bathroom pod.

FIG. 3B is a modified form of the enlarged area of detail shown in FIG.2C.

FIG. 3C is a further modified form of the enlarged area of detail shownin FIG. 2C.

FIG. 3D is a still further modified form of the enlarged area of detailshown in FIG. 2C

FIG. 4A is a top oriented perspective view of a prefabricated bathroomfloor component that is similar or identical to that depicted in FIG. 1prior to being encapsulated with a waterproof strengthening membrane andwhich employs a perimeter peripheral member. An opening without a raisedwall platform, where a door may be installed, is shown toward the frontof the prefabricated bathroom floor component.

FIG. 4B is a top oriented perspective view of a prefabricated bathroomfloor component that is similar or identical to that depicted in FIG. 1prior to being encapsulated with a waterproof strengthening membrane andwhich employs a reinforced peripheral strengthening member, and a bordermember.

FIG. 4C is a top oriented perspective view of a prefabricated bathroomfloor component that is similar to that depicted in FIG. 4A prior tobeing encapsulated with a waterproof strengthening membrane and whichdoes not employ a transverse strengthening member.

FIG. 4D is a top oriented perspective view of a prefabricated bathroomfloor component that is similar to that depicted in FIG. 4B prior tobeing encapsulated with a waterproof strengthening membrane and whichdoes not employs a transverse strengthening member.

FIG. 5A is a bottom oriented perspective view of the prefabricatedbathroom floor component of FIG. 4A.

FIG. 5B is a bottom oriented perspective view of the prefabricatedbathroom floor component of FIG. 4B.

FIG. 5C is a bottom oriented perspective view of the prefabricatedbathroom floor component of FIG. 4C.

FIG. 5D is a bottom oriented perspective view of the prefabricatedbathroom floor component of FIG. 4D.

FIG. 6 is a perspective view of the prefabricated bathroom floorcomponent of FIGS. 4-5 after being coated with a waterproof sealant.

FIG. 7A is a cross-sectional exploded elevational view of the embodimentof a prefabricated bathroom floor component shown in FIG. 3A.

FIG. 7B is a cross-sectional exploded elevational view of the embodimentof a prefabricated bathroom floor component shown in FIG. 15B.

FIG. 7C is a cross-sectional exploded elevational view of the embodimentof a prefabricated bathroom floor component shown in FIG. 15C.

FIG. 7D is a cross-sectional exploded elevational view of the embodimentof a prefabricated bathroom floor component shown in FIG. 18D.

FIG. 7E is a cross-sectional exploded elevational view of the embodimentof a prefabricated bathroom floor component shown in FIG. 23 .

FIG. 8A depicts a waterproof sealant being applied to the prefabricatedbathroom floor component of FIG. 3A.

FIG. 8B depicts a waterproof sealant being applied to the prefabricatedbathroom floor component of FIG. 15C.

FIG. 8C depicts a waterproof sealant being applied to the prefabricatedbathroom floor component of FIG. 15D.

FIG. 8D depicts a waterproof sealant being applied to the prefabricatedbathroom floor component of FIG. 18D.

FIG. 8E depicts a waterproof sealant being applied to the prefabricatedbathroom floor component of FIG. 23 .

FIG. 9A is a flow chart depicting a method of manufacture and use ofprefabricated bathroom floor components according to an embodiment ofthe present disclosure.

FIG. 9B is a flow chart depicting a method of manufacture and use ofprefabricated bathroom floor components according to another embodimentof the present disclosure.

FIG. 9C is a flow chart depicting a method of manufacture and use ofprefabricated bathroom floor components according to a furtherembodiment of the present disclosure.

FIG. 10A is a flow chart depicting the method of manufacture and use ofprefabricated bathroom floor components according to FIG. 9A.

FIG. 10B is a flow chart depicting the method of manufacture and use ofprefabricated bathroom floor components according to FIG. 9B.

FIG. 10C is a flow chart depicting the method of manufacture and use ofprefabricated bathroom floor components according to FIG. 9C.

FIG. 11 is an exploded perspective view of a bathroom pod constructedwith a prefabricated floor component according to a third embodiment ofthe present disclosure.

FIG. 12 is a perspective assembled view of the bathroom pod constructedwith a prefabricated bathroom floor component of FIG. 11 .

FIG. 13 is an enlarged detail view taken from FIG. 12 .

FIG. 14 is a front cross-sectional elevational view of the bathroom podof FIG. 12 , taken along lines 14-14 thereof.

FIG. 15A is a side cross-sectional elevational view of the bathroomfloor component of FIG. 12 , taken along lines 15A-15A thereof.

FIG. 15B is an enlarged detail view taken from FIG. 14 , showing theinternal details of the fastened connection of the prefabricatedbathroom floor component to the walls of the bathroom pod.

FIG. 15C is an enlarged detail view taken from FIG. 14 , showingalternative internal details of the fastened connection of theprefabricated bathroom floor component to the walls of the bathroom pod.

FIG. 16A is a top oriented perspective view of a prefabricated bathroomfloor component before completion.

FIG. 16B is a bottom oriented perspective view of the prefabricatedbathroom floor component of FIG. 16A.

FIG. 17A is a top perspective view of the bathroom floor component ofFIG. 16A after being encapsulated in a waterproof membrane.

FIG. 17B is a bottom perspective view of the bathroom floor component ofFIG. 16B after being encapsulated in a waterproof membrane.

FIG. 18A is a top plan view of a prefabricated bathroom floor moduleaccording to a third embodiment of the invention.

FIG. 18B is a bottom plan view of the bathroom floor component of FIG.18A.

FIG. 18C is a cross-sectional elevational view of the bathroom floorcomponent taken along lines 18C-18C of FIG. 18A.

FIG. 18D is a cross-sectional elevational view of the floor module takenalong lines 18D-18D of FIG. 18A.

FIG. 18E is a top perspective view of the bathroom floor component ofFIG. 18A without longitudinal or anti-compression elements.

FIG. 18F is a bottom perspective view of the bathroom floor component ofFIG. 18A without longitudinal or anti-compression elements.

FIG. 18G is a top perspective view of the bathroom floor component ofFIG. 18A with anti-compression elements.

FIG. 18H is a bottom perspective view of the bathroom floor component ofFIG. 18A.

FIG. 18I is a top perspective view of the bathroom floor component ofFIGS. 18E and 18G after being coated with a waterproof sealant.

FIG. 18J is a bottom perspective view of the bathroom floor component ofFIGS. 18F and 18H after being coated with a waterproof sealant.

FIG. 19 is a perspective exploded view of a fourth embodiment of theinvention.

FIG. 20 is a bottom plan exploded view of representative floor sectionsthereof.

FIG. 21A is a top plan assembled view of the bathroom floor component ofthe fourth embodiment after assembly and coating with a waterproofmembrane.

FIG. 21B is a bottom plan assembled view of the bathroom floor componentof the fourth embodiment after assembly and coating with a waterproofmembrane.

FIG. 22A is a cross-sectional elevational view taken along lines 22-22of FIG. 21 .

FIG. 22B is a cross-sectional elevational view taken along lines 22-22of FIG. 21 , but where the floor member is comprised of two stackedfloor panels.

FIG. 23A is a cross-sectional elevational view taken along lines 23-23of FIG. 21 .

FIG. 23B is a cross-sectional elevational view taken along lines 23-23of FIG. 21 , but where the floor member is comprised of two stackedfloor panels.

FIGS. 24-26B depict a fifth embodiment of the invention, which issubstantially the same as the embodiment shown in FIGS. 19-23 but with asingle-panel floor member.

FIG. 24 is a perspective exploded view of a fifth embodiment of theinvention.

FIG. 25 is a bottom plan view of the bathroom floor component of FIG. 24.

FIG. 26A is a top plan view of the bathroom floor component of FIGS. 24and 25 after being coated with a waterproof membrane.

FIG. 26B is a bottom plan view of the bathroom floor component of FIGS.24 and 25 after being coated with a waterproof membrane.

FIG. 27 is a bottom exploded perspective view of a bathroom podconstructed with a prefabricated bathroom floor component according to asixth embodiment of the present disclosure.

FIG. 28 is a top perspective view thereof.

FIG. 29 is a close up of the area of detail shown in FIG. 28 .

FIG. 30 is a cross-sectional elevational view taken along lines 30-30 ofFIG. 28 .

FIG. 31 is a cross-sectional elevational view taken along lines 31-31 ofFIG. 28 .

FIG. 32A is an enlargement of the area of detail shown in FIG. 30 ,showing internal details of the fastened connection of the prefabricatedfloor component to the walls of the bathroom pod.

FIG. 32B is a modified form of the enlarged area of detail shown in FIG.32A.

FIG. 33 is a top oriented perspective view of a prefabricated bathroomfloor component that is similar or identical to that depicted in FIG. 27prior to being encapsulated with a waterproof strengthening membrane.

FIG. 34 is a top oriented perspective view of the prefabricated bathroomfloor component of FIGS. 27 and 33 after being coated with a waterproofsealant.

FIG. 35 is a bottom oriented perspective view of the prefabricatedbathroom floor component of FIGS. 27 and 33 after being coated with awaterproof sealant.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the disclosure,examples of which are illustrated in the accompanying drawings. Whereverpossible, the same reference numbers will be used throughout thedrawings to refer to the same or like parts. In some cases, a referencenumber will be indicated in this specification and the drawings willshow the reference number followed by a letter for example, 100 a, 100 bor a prime indicator such as 100′, 100″ etc. It is to be understood thatthe use of letters or primes immediately after a reference numberindicates that these features are similarly shaped and have similarfunction such as is often the case when geometry is mirrored about aplane of symmetry. For ease of explanation in this specification,letters or primes will often not be included herein but may be shown inthe drawings to indicate duplications of features discussed within thiswritten specification.

Accordingly, the apparatus components have been represented whereappropriate by conventional symbols in the drawings, showing only thosespecific details that are pertinent to understanding the embodiments ofthe present invention so as not to obscure the disclosure with detailsthat will be readily apparent to those of ordinary skill in the arthaving the benefit of the description herein.

The embodiments of the present disclosure typically include combinationsof structural components and manufacturing, installation and use stepsrelated to the creation of a variety of bathroom floors including showerfloors that may be used in a bathroom floor component or the like.

In this document, relational terms, such as “first” and “second,” “top”and “bottom,” and the like, may be used solely to distinguish one entityor element from another entity or element without necessarily requiringor implying any physical or logical relationship or order between suchentities or elements.

The terms “comprises,” “comprising,” “comprise”, “including”, “include”or any other variation thereof are intended to cover a non-exclusiveinclusion, such that a process, method, article, or apparatus thatcomprises a list of elements need not necessarily include only thoseelements, but may include other elements not expressly listed orinherent to such process, method, article, or apparatus.

The term “plurality of” as used in connection with any object or actionmeans two or more of such objects or actions.

As used herein, the articles “a” and “an” are intended to include one ormore items, and may be used interchangeably with “one or more.” Whereonly one item is intended, the term “one” or similar language is used.Also, as used herein, the terms “has”, “have”, “having”, “with” or thelike are intended to be open-ended terms. Further, the phrase “based on”is intended to mean “based, at least in part, on” unless explicitlystated otherwise.

Terms such as “wall coverings”, “floor covering”, “wall or flooringmaterial,” “floor and wall covering,” “flooring material” and “coveringmaterial” mean one or more of ceramic, natural stone or other tile,stone, granite, marble, cultured marble, solid surface, or any othersurface (e.g. stone), or non-slip finished shower surfaces such asvinyl, epoxy, or plastic, stucco, concrete and mortar surfaces, whetheror not applied or combined with adhesives or other substances, and anyother material or materials used to provide a finished surface.

The term “tiled” means any surface having floor or wall coveringmaterials, such as one or more of ceramic, porcelain, natural stone orother tile, stone, granite, marble, cultured marble, solid surface orany other surface (e.g., stone), or non-slip finished shower surfacessuch as vinyl, epoxy, or plastic, stucco, concrete and mortar surfaces,whether or not applied or combined with adhesives or other substances,and any other material or materials used to provide a finished surface.

The term “non tileable” means one or more surfaces or structuralcomponents which are not capable of receiving wall or floor material orwere not designed, marketed or sold with the intention of being tileableor tiled, and in fact are not tiled.

The term “tileable” or “ready-to-tile” means one or more surfaces orstructural components which are capable of receiving wall or flooringmaterial, whether through the use of adhesives or any other means ofattachment, such as clips, straps or other mechanical fasteningstructure(s).

A “fastener” or “fastening” may include anything known in the art forfastening including, but not limited to, cap screws, bolts, screws,clips, adhesives, etc.

The term “standard drain” or “drain assembly” means any kind of drainmade of any kind of material, including but not limited to metal orplastics, and with any kind of connection to a drain system such as awaste water system, including but not limited to a solvent weld drain, awelded connection drain, a hub (outside caulk) drain, a spigot drain, ahubless spigot drain, a hubless drain, an inside caulk (gasket) drain, ahubbed (push on) drain, a compression drain, and a clamping ring drain.

The term “trench drain” means any linear drain and any linear trenchadapted to direct water to a building drain, and contemplates any typeof drain fixture.

The term “drain area” or “drain aperture” means an area in which a drainis either to be formed or installed, or is actually formed or installed,in a shower pan and/or bathroom floor.

The term “molded” means any component that is formed with a finishedproduct at the time that the finished product is molded.

The term “plastic” means any foam, plastic, polyurethane, PVC, ABS,polyethylene or other material having characteristics similar thereto.

The term “foam” means any rigid polyurethane foam or any other materialhaving characteristics similar thereto.

The terms “pitch” or “slope” mean the change in elevation per unit oflength of floor. A typical shower floor pitch is ¼″ per foot, althoughany pitch is deemed to be within the scope of the inventions disclosedherein. Non shower pitch areas typically would have pitch which isbetween ⅛′ per foot to 1/16″ per foot more or less. Shower surfaces andnon-shower wet areas are typically pitched toward the drain, encouragingwater to flow to the drain. Dry pitched areas may or may not be pitchedto a drain.

As used herein, a “frame member” or “strengthening member” may be astructural strength enhancing member that is made from any material thatwill have the tendency to increase the strength of the bathroom floorcomponents of this invention when incorporated into such bathroom floorcomponents, and may have a thickness of ¼″ inch to 2 inches more orless, along with any length and width.

As used herein, an “anti-compression member” is a weight-supportingelement adapted to be incorporated into or otherwise used to supportweight to avoid deformation of a component or structure by aweight-bearing object.

As used herein, a “concrete member” or “concrete frame member” is aframe member made or cut from concrete wall board or porcelain cement orthe like, and may have any thickness, for example ½ inch to 2 inches.Other forms of concrete or cement may be used to manufacture a concretemember, etc.

As used herein, a “foam and/or plastic member” may be any type of foamor plastic material such as polyurethane, PVC, ABS, polyethylene, andother plastics and/or foam, including an XPS (extruded polystyrene) foamthat is commercially available, that is cut or manufactured to size, andthat may be of any desired density depending on the specific need forsuch foam and/or plastic member. Other types of foam and plastic may beused to manufacture a foam and/or plastic member.

As used herein, a “bathroom pod,” “prefabricated pod bathroom,”“bathroom pod chamber,” or the like, is a prefabricated, portable pod,from time of manufacture to time of final installation, comprisingbathroom features such as one or more floor areas, walls, ceiling,plumbing fixtures, electrical features, decorative floor and wallcovering material, etc.

The embodiments disclosed herein may be employed in, by example but notby way of limitation, residential single and multi-family complexes,hospitals, health care facilities, nursing homes, assisted living andaging in place facilities dormitories, hospitality facilities, hotels,military housing, time shares, commercial, military, student and/orindustrial facilities, and any other installations in which one or morebathrooms pods are incorporated into the construction.

First, a prefabricated bathroom chamber or bathroom pod, or pod or abathroom pod floor component that may be employed according to one ormore embodiments of the present disclosure suitable for buildingcommercial projects, will be discussed. Then, a pod bathroom floorcomponent that may be used in such a bathroom pod or other similarapplications, as a replacement in the field, or in a custom application,will be discussed. Later herein, a method for fabricating and/or usingone or more component embodiments will be described. This methodologywill be repeated for similar or related embodiments.

Representative Prefabricated Bathroom Pod with a Raised PeripheralStrengthening Wall-Support Platform

Given the size of the typical bathroom pod floor component and theweight of the bathroom pod once assembled, a robust method for resistingsagging, twisting, bending and other destructive forces during lifting,transport and installation of the bathroom pods is desired, as well asthe needed structure to strengthen the floor component and support theweight of the bathroom walls and wall coverings, bathroom floors andfloor coverings, accessories and ceiling panel.

A bathroom pod 100 according to an embodiment of the present disclosurewill now be discussed with reference to FIGS. 1-6 . The bathroom pod 100as shown may comprise a ceiling 102, a plurality of walls 104,electrical wiring 106, plumbing 108, and a bathroom floor component300/300 a. As shown in FIGS. 4 and 5 , the underlying bathroom floorcomponent 300 may include one or more transverse strengthening members302, which strengthening members may be made of wood, concrete wallboardmaterial (e.g., HARDIE® Board manufactured by James Hardie BuildingProducts, Inc.) porcelain, metal, extruded thermoplastics, reinforcedthermoplastics, etc., or the like, and that is adhered to one or morefoam floor panels 304.

As seen in FIG. 6 , one or more floor panels 304 (and strengtheningmembers 302 if present) are not typically seen in the finished bathroomfloor component 300 as assembled since the entire floor component 300 isencapsulated in a waterproof material, creating an encapsulation layer325, which will be discussed in more detail below. The operative walland floor areas of the pod 100 (including encapsulation layer 325) areusually covered by decorative and/or functional wall and floor covering390, 394, respectively, such as wall and floor tile, respectively, orthe like, as is well known. An ingress/egress area 180 may be providedto permit unencumbered access to the bathroom pod.

Further, in some embodiments, a weight bearing raised platform 376 forsupporting the pod walls is formed from the same one or more foam floorpanels 304 referenced above to create a raised peripheral planar wallsupport surface 377 defining an outer raised platform perimeter ofbathroom floor component 300. Additionally, one or more of the foamfloor panels 304 may define a drain aperture 378, and define slopedupper surfaces 380 that are directed toward the drain aperture 378.

Typically, as seen in FIGS. 1-3 , the walls 104 may connect the ceiling102 to the bathroom floor component 300, the electrical wiring 106 isattached to at least one of the plurality of walls 104 and/or theceiling 102, and the plumbing 108 is attached to at least one of theplurality of walls 104 or the bathroom floor component 300. It iscontemplated that the ceiling and/or one or more of the plurality ofwalls and/or plumbing fixtures/accessories may be omitted from the pod100 in embodiments of the present disclosure. Also, various light andplumbing fixtures, or any other accessories, may or may not be present.Also, the walls may be supported by a plurality of strengthening membersassociated with the raised platform which strengthening members would beselected from the group of compression-resistant materials and productssuch as polyurethane, wood, bushings and grommets. In other embodiments,ceiling 102 may be manufactured and employed in the manner described inconnection with bathroom floor component 300.

Put another way, the walls may connect the ceiling to the bathroom floorcomponent 300. The walls may include bottom frame members 112 which areadapted to align and be coplanar with upper surface 377. A plurality ofhollow fastener-receiving journals or bushings 116 may be disposed inthe plurality of apertures 114 defined by raised platform 376. Thesejournals 116 may act as alignment features when the walls are fastenedto the bathroom floor component 300, act to protect the integrity ofapertures 114, which in some embodiments are formed in polystyrene orother relatively soft foam, and in other embodiments a more rigid foamsuch as polyurethane, and act to transfer weight from the walls 104 tothe sub-floor (not shown) supporting pod 100. In doing so, the raisedplatform 376 is protected from crushing. The hollow interiors ofbushings 116 allow fasteners 120 to extend through apertures 114 inraised platform 376 through the bottom wall of frame members 112 (seeFIGS. 2C, 2D and 3 ). As seen in FIGS. 4 b and 5B, anti-compressionmembers 379, which may be wood, polyurethane, metal or any othermaterial or apparatus, may be incorporated within the raised platform376 to help in transferring the weight of the pod walls 104 from theraised platform to the sub floor (not shown). One or more of any of theraised platform anti-compression members 379 may be used in anycombination in the raised platform. In embodiments, voids for receivingthe anti-compression members 379 and are machined into platform 376. Inother embodiments, such voids are created during manufacturing of theraised platform.

Focusing on FIG. 3A, it can be seen that the bushings 116, which arepreferably fabricated of metal, although any material having goodcompression resistance is suitable, transfer weight from the walls downto the support surface or substrate (not shown) on which the bathroomfloor component 300 will sit. Any suitable fastener 120 may be usedincluding nuts and bolts, screws, adhesive, and the like. Bottom framemembers may be in the form of standard U-shaped channels, rectangularstructural members such as 2×4s or 4×4s, or the like, to which areattached the wall studs 110. The U-shaped channels and/or rectangularstructural members 112 may be referred to as a bottom wall strengtheningmember, bracket, track or tray, and may be used to connect the wallstuds 110 to the upper surface 377 of raised platform 376. The U-shapedchannels and/or bottom frame members 112 are preferably aligned with theupper surfaces 377 of raised platform 376. The fasteners 120 may engageone or more of the bottom frame members 112 through apertures 114. Inembodiments, the bushings 116 may be disposed in the apertures 114,which then support the bottom frame members 112 and the anti-compressionmembers as applicable. The fasteners 120 may extend through the bushings116 so that the bushings 116 surround the fasteners 120.

Similarly, FIGS. 2A thru 2D depict the bathroom pod 100 as assembled.Some of the plumbing accessories are more easily seen including theshower accessories. Other features, configurations, and accessories arepossible in other embodiments of the present disclosure.

The ceiling 102 may be monolithic, crack-proof, and water proof. Theelectrical wiring 106 and the plumbing 108 may be pretested and codecompliant. The walls 104 may have moisture, mold and abuse resistantwallboard 107. Engineered steel framing studs 110 may hold the walls,and the pod floor component 100 as a whole, together. Accessories suchas, but not limited to, a sink rail 118, mirror 111 and foot rest 113may also be provided. One or more of these features or accessories maybe omitted in other embodiments of the present disclosure.

As can be seen, any completed, prefabricated bathroom chamber or podsuch as pod 100 may speed up construction of a building by providing acompletely finished modular room that is clean and ready forinstallation and use. Once properly positioned, physical placementwithin the building as well as plumbing and wiring hook ups are all thatis needed before the bathroom is operational.

Turning to FIGS. 4 and 5 , it can be understood that the bathroom podfloor component 300 is assembled as a collection of component parts,comprising (as will be seen in connection with FIGS. 7-10 ) one or morefloor panels encapsulated within a one piece, waterproof, rigid layer325 to result in a monolithic, extremely strong bathroom floor memberthat resists bending, sagging and twisting. The pre-encapsulatedbathroom floor as shown in FIGS. 4A, 4B, 5A and 5B may comprise anynumber of transverse strengthening members or stringers 302. One or morefoam floor-forming members 304 may be disposed between the one or moreplurality of strengthening members 302. More particularly, at least oneof the plurality of foam floor members 304 may be disposed betweenadjacent transverse cross-brace strengthening members 302. In someembodiments, a single longitudinal strengthening member 302 and twopanels of foam 304 may be employed, etc. to form the bathroom floorcomponent 300. In other embodiments, the floor and perimeter raisedplatform 376 are formed of a single sheet of closed cell foam, and mayor may not be encapsulated in the waterproof rigid layer.

More specifically, at least one or more of the plurality of foam members304 may be bonded to at least one or more of the plurality of outsideperipheral strengthening members 374, and to at least one or more of theplurality of transverse cross-brace strengthening members 302. Thebonding may be intermittent or may cover substantially the entireinterface between the foam member and the peripheral strengtheningmember. Any suitable bonding agent may be used, such as glue, latexmodified rapid setting material, etc., as will occur to those of skillin the relevant art.

As best seen in FIGS. 4-5 , one of the foam members 304 may define adrain aperture 378. The drain aperture 378, as well as any contour,e.g., slope or pitch to the upper surface of floor panels 304, may bemilled or drilled, etc. using a CNC (computer numerically controlled)router or milling machine, or other aperture-forming technique, etc.Alternatively, such structural features may be formed in a moldingprocess. In like manner, contour, e.g., support ribs (not shown), may beformed in the lower surface of floor members 304. Later, a drainassembly (such as the linear trench and linear drain 391 shown in thefigures, or a circular drain, etc. may be inserted into the drainaperture 378 during the fabrication of the bathroom floor component aswill be discussed in more detail below.

As seen in FIGS. 4B, 5B and 6 , a modified floor component 300 a employsa prefabricated raised platform 376 having one or more anti-compressionelements 379 integrated therewith. The anti-compression elements 379transfer weight from the pod walls 104 to the substrate which supportsthe floor component 300 a. Anti compression elements 379 may becomprised of wood, plastic, polyurethane, metal, pvc, concrete,porcelain cement or any suitable material capable of transferring weightforces exerted by the walls (which includes the weight of the ceiling102 and the accessories and other items attached to the pod 100) toavoid crushing or otherwise distorting the raised platform 376. Anynumber of elements 379 may be employed, with each having the same sizeor shapes and/or dimensions, or having unique shapes, sizes anddimensions. Alternatively, the raised platform 376 may be comprisedentirely of material which is capable of supporting the weight of thewalls 104 and attachments thereto.

FIGS. 4A-5B show floor components 300 and/or 300 a prior to beingencapsulated with a waterproof membrane. FIG. 6 shows floor components300 and/or 300 a after being encapsulated with a waterproof membrane325. As can be seen, strengthening members 302, as well as theperipheral edges of drain fixture 391, can no longer be seen after floorcomponent 300/300 a has been encapsulated.

The bathroom floor component 300 c shown in FIG. 4C is in most materialrespects the same as the bathroom floor component of FIG. 4A, but doesnot have longitudinal strengthening member(s) 302. Instead, it is asingle-panel floor component. In embodiments, bathroom floor component300 c may be coated with waterproof membrane 325, or may be uncoated,such as in cases where it is manufactured of water impervious material.In the latter case, no additional waterproofing, such as in the form ofwaterproof membrane 325, is necessary.

The bathroom floor component 300 d shown in FIG. 4D is in most materialrespects the same as the bathroom floor component of FIG. 4B, but doesnot have longitudinal strengthening member(s) 302. Instead, it is asingle-panel floor component. In embodiments, bathroom floor component300 d may be coated with waterproof membrane 325, or may be uncoated,such as in cases where it is manufactured of water impervious material.In the latter case, no additional waterproofing, such as in the form ofwaterproof membrane 325, is necessary.

Waterproof Membrane

As stated previously, it has been discovered that encapsulating orcoating the bathroom floor component or other constituent element of thefloor with a waterproof membrane by applying a waterproof sealant orother water-impervious material to the entire assembly significantlyadds to the strength of the bathroom floor component, and alsocontributes to the watertight quality of the component, though awaterproof membrane may not be required when a one-piece closed cellfloor panel and/or raised support platform are used for the bathroomfloor component 300/300 a. FIG. 6 shows a representative bathroom floorassembly after having been sprayed with such a membrane 325 during abathroom floor component manufacturing process. FIGS. 7-8 show that abathroom floor component, such as components 300 and 300 a, may be spraycoated with a waterproof sealant or other protective waterproof layer325 to create the waterproof membrane. Other methods of application arepossible, including powder coating, baking, curing, etc. Teachings ofsuitable coating materials, techniques and resulting structures aredisclosed in U.S. Pat. Nos. 8,918,926, 9,107,545 and 9,775,472 toHerring, the disclosures of which are incorporated by reference hereinas though fully set forth herein.

The bathroom floor component of FIG. 6 may be comprised of, inembodiments, a bathroom floor member 300/300 a made of one or moreplastic or foam members 304 attached to one or more longitudinal and/orperipheral strengthening members 302, 374, after having been coated withthe waterproof membrane 325. The type of membrane material may vary, butmay take the form of any suitable commercially available polyurethane,polyurea, or the like.

FIG. 7A is a cross-sectional exploded elevational view of the embodimentof a prefabricated bathroom floor component shown in FIG. 3A. FIG. 7B isa cross-sectional exploded elevational view of the embodiment of aprefabricated bathroom floor component shown in FIG. 15B. FIG. 7C is across-sectional exploded elevational view of the embodiment of aprefabricated bathroom floor component shown in FIG. 15C. FIG. 7D is across-sectional exploded elevational view of the embodiment of aprefabricated bathroom floor component shown in FIG. 18D. FIG. 7E is across-sectional exploded elevational view of the embodiment of aprefabricated bathroom floor component shown in FIG. 23 .

FIG. 8A depicts a waterproof sealant being applied to the prefabricatedbathroom floor component of FIG. 3A. FIG. 8B depicts a waterproofsealant being applied to the prefabricated bathroom floor component ofFIG. 15C. FIG. 8C depicts a waterproof sealant being applied to theprefabricated bathroom floor component of FIG. 15D. FIG. 8D depicts awaterproof sealant being applied to the prefabricated bathroom floorcomponent of FIG. 18D. FIG. 8E depicts a waterproof sealant beingapplied to the prefabricated bathroom floor component of FIG. 23 .

INDUSTRIAL APPLICABILITY

As seen in connection with FIGS. 9-10 , in practice, a bathroom chamberor pod, and a pod bathroom floor component, which may or may not employa support and/or strengthening framework, may be designed, specified,sold, manufactured, bought, etc., in the commercial or customapplication markets according to any of the embodiments discussedherein. That is to say, any of the embodiments described herein may beused to retrofit, repair or refurbish a building or prefabricatedbathroom pod, or bathroom floor, or may be used to construct a newbathroom pod for or in a building of any type.

The prefabricated bathroom pods, the bathroom floor components, and anysupport apparatus disclosed herein may provide easier, quicker and lessexpensive ways to construct buildings.

It is to be understood that the arrangements disclosed herein aresuitable for use with any drain location, even though embodiments areshown using specific drain locations. Such locations are shown forexample purposes only, it being understood that the principles of thepresent disclosure may be applied to create more embodiments.

In broader terms than heretofore discussed, a method for fabricatingand/or using embodiments of the present disclosure may be characterizedas follows with reference to FIGS. 9-10 .

With reference to FIG. 9A, the method 400 may comprise the followingsteps presented in no particular order: step 402 may include positioningeither two or more plastic and/or foam floor members 304 that are spacedapart from each other, step 404 may include providing one or morelongitudinal strengthening cross-brace members 302, and step 406 mayinclude attaching each of the one or more plastic and/or foam floormembers 304 to the at least one longitudinal strengthening members 302.Referring still to FIG. 9A, in some embodiments, the step 406 ofattaching at least one or more of the plurality of plastic and/or foammembers 304 to at least one or more of the plurality longitudinaltransverse strengthening members 302, includes bonding using an adhesive(see step 408).

The method 400 may further comprise milling or otherwise rendering adrain aperture in at least one or more of the floor members, and millingthe top surface of one or more of the floor members, or portionsthereof, with a pitch, such as but not by way of limitation, toward thedrain aperture at any appropriate time(s) (step 414).

In some embodiments, the method 400 may further comprise applying awaterproof sealant to the one or more of the plurality of floor membersand the longitudinal strengthening member(s) 302 (step 416).

Looking now at FIG. 10A, another method 500 of fabricating a podbathroom floor component will now be described.

The method 500 may comprise machining a first plastic and/or foam floormember with at least one sloped surface extending downwardly toward adrain aperture and a peripheral strengthening raised platform member(step 502), machining a second foam floor member with a peripheralstrengthening raised platform member (step 503), providing one or morelongitudinal strengthening member(s) (step 504), joining the first andsecond floor members to opposite side edges of the longitudinalstrengthening member (step 506), and applying a waterproof sealant tothe assembly (step 514).

Step 506 may include attaching the floor members to the longitudinalstrengthening member by fastening or bonding using an adhesive (step510).

The method may further comprise creating a contour in the upper surfaceof the longitudinal strengthening member(s) 302 to coincide with thecontour of the upper surface of the adjacent floor members to render theupper surfaces of the longitudinal strengthening member(s) 302 coplanarwith the contour of the upper surface of the adjacent floor members, topermit application of a floor covering (e.g., floor tile) that is to beattached to the floor members and the longitudinal strengtheningmember(s), if any (step 516).

Optionally, a raised peripheral support platform member, such as raisedperipheral platform 376 shown in FIGS. 1-6, 976 shown in FIGS. 18Athrough 18H, 1076 shown in FIGS. 19 through 26, and 1176 shown in FIGS.27 through 35 , may be formed in the floor member(s), and in some casescombined with peripheral support and/or framing members disclosedherein, to create a support for the bottoms of pod walls 104.

As alluded to earlier herein, once the floor component has beenmanufactured with a wall strengthening raised peripheral platform, thenit may be attached to the walls, and indirectly the ceiling, etc., tomake an assembled bathroom pod.

With reference to FIG. 9B, the method comprises providing a singlebathroom floor panel, such as panel 1004 shown in FIG. 24 , and asupport frame, such as frame 1050 shown in FIG. 24 . The panel(s)defines a peripheral raised support platform 1076 which in turn definesapertures 120 through which fasteners may be passed to be used during anattachment step to be discussed in more detail below.

At step 414, a drain aperture is milled or otherwise rendered in thefloor panel, as well as any desired floor pitch/slope.

In step 406, the raised platform 1076 of the bathroom floor component isplaced in registry with the floor frame 1050.

The bathroom floor panel 1004 and frame 1050 are then coated with awaterproof coating 325 as described above, which not only creates awaterproof floor component but adds significant strength and rigidity tothe bathroom floor component and, thereby, to the pod overall.

The raised support platform 1076 coincides substantially with afootprint defined by lower edges of the pod walls 104. The lower edgesof the pod walls 104 are placed in registry with the raised platform1076 and fastened to the pod walls 104. Wall and floor covering materialsuch as wall and floor tile 390, 394 may thereafter be applied to thepod walls and floor in a manner well known to those skilled in the art.A sturdy pod is thus created, and can be transported to and installed ata construction site.

FIG. 10B depicts a process for manufacturing a pod bathroom floorcomponent using a floor member comprised of a single floor panel, suchas panel 1004 of FIGS. 24-26 . In this embodiment, a pod bathroom floorcomponent is produced by providing a single floor panel which definesraised support platform 1076, providing floor contour to an uppersurface of the floor panel, including a drain aperture, placing theraised platform 1076 of the bathroom floor component in registry withthe lower edges of the pod walls 104, and fastening the floor componentto the pod walls. Wall and floor covering material, such as wall andfloor tile 390, 394, may be applied to the pod walls and floor in amanner well known to those skilled in the art.

FIG. 9C shows a further method comprised of: providing two or morebathroom floor panels, such as panels 1004L, 1004R shown in FIG. 19 ,and a support frame, such as frame 1050 shown in FIG. 19 . The panelsdefine a peripheral raised support platform 1076 which in turn definesapertures 120 through which fasteners may be passed to be used during anattachment step to be discussed in more detail below.

At step 414, a drain aperture is milled or otherwise rendered in one ofthe floor panels, as well as any desired floor pitch/slope.

In step 406, the raised platforms 1076L and 1076R of the bathroom floorpanels 1004L, 1004R are placed in registry with the floor frame 1050.

The bathroom floor panels 10041, 1004R and frame 1050 are then coatedwith a waterproof coating 325 as described above, which not only createsa waterproof floor component but adds significant strength and rigidityto the bathroom floor component and, thereby, to the pod overall.

The raised support platforms 1076L, 1076R coincide substantially with afootprint defined by lower edges of the pod walls 104. The lower edgesof the pod walls 104 are placed in registry with the raised platforms1076L, 1076R and fastened to the pod walls 104. Wall and floor coveringmaterial such as wall and floor tile 390, 394 may thereafter be appliedto the pod walls and floor in a manner well known to those skilled inthe art.

FIG. 10C shows a still further process for manufacturing a pod bathroomfloor component using a floor member comprised of two or more floorpanels, such as panels 1004L, 1004R of FIGS. 19-23 . In this embodiment,a pod bathroom floor component is produced by providing a single floorpanel which defines raised support platform 1076L, 1076R, providing anydesired floor contour to an upper surface of the floor panels, includinga drain aperture, placing the raised platforms 1076L, 1076R of thebathroom floor component in registry with the lower edges of the podwalls 104, and fastening the floor component to the pod walls. Wall andfloor covering material, such as wall and floor tile 390, 394, may beapplied to the pod walls and floor in a manner well known to thoseskilled in the art.

Representative Prefabricated Bathroom Floor Component without WeightBearing Perimeter Raised Platform.

FIGS. 11 — 17B depict a further embodiment of the invention, in whichbathroom floor component 720 is comprised of one of more longitudinalstrengthening members 702, peripheral strengthening members 774, andfoam floor members 704. In this embodiment, no perimeter raisedplatforms are employed, and a third party substrate is provided tosupport the bathroom floor component.

The bathroom pod 100 as shown may comprise a ceiling 102, a plurality ofwalls 104, electrical wiring 106, plumbing 108, and a bathroom floorcomponent. As shown in FIGS. 16A and 16B, the underlying bathroom floorcomponent 700 may include at least a first longitudinal strengtheningmember 702 that is adhered to one or more foam floor panels 704, whichare not typically seen in the bathroom floor component 100 as assembledsince the entire floor component 700 is encapsulated in a waterproofmaterial 325, and usually covered by decorative and/or functional walland floor covering 390, 394, respectively, such as wall and floor tile,respectively, or the like, as is well known. And similarly, bathroomfloor component 700 as shown in FIGS. 16A and 16B may include one ormore perimeter strengthening members 774, which completely or partiallysurround(s) foam floor panels 704. Further, in some embodiments,perimeter strengthening members 774 are attached to peripheral edges ofthe floor members 704 to define a reinforced outer perimeter of thebathroom floor component 700. Additionally, one or more of the foamfloor panels 704 may define a drain aperture 378, may employ a circularor linear drain 391 such as a trench drain as shown, and define slopedupper surfaces 380 that are directed toward the drain 391.

In this embodiment, a support panel or substrate 785 supports and is thesubstrate for bathroom floor component 700, and the outer periphery ofbathroom floor component 700 fits substantially within the area definedby inner-facing surfaces of wall board material 107.

Support substrate 785 in turn is attached to bathroom pod 100 in anydesirable manner. One such manner is to connect the substrate to thewalls 104 of the pod 100. In embodiments, substrate 785 may be connectedto walls 104 by mechanical connection therebetween, an example of whichcan be seen in the drawings. Fasteners 120, such as nut and boltarrangements, may connect the substrate 785 to the pod wall bottom framemembers 112. In this way, the bathroom floor component 700 is supportedby substrate 785 and walls 104 when the pod 100 is not supported itselfon a floor such as a factory floor, transport vehicle or final buildingfloor slab. Support substrate 785 may be manufactured of PVC, wood,metal, or any other material capable of supporting the weight of thefloor member 700.

Any suitable fastener 120 may be used including nuts and bolts, dry wallscrews and the like. Bottom wall frame members 112 are preferablyaligned with upper peripheral surfaces of substrate 785. The fasteners120 may engage one or more of the bottom frame members 112 throughapertures 714 defined by the substrate 785.

Typically, as seen in FIGS. 11-15B, the walls 104 may connect theceiling 102 to the bathroom floor component 700, the electrical wiring106 is attached to at least one of the plurality of walls 104 and/or theceiling 102, and the plumbing 108 is attached to at least one of theplurality of walls 104 or the bathroom floor component 700. It iscontemplated that the ceiling and/or one or more of the plurality ofwalls and/or plumbing fixtures/accessories may be omitted from the pod100 in other embodiments of the present disclosure. Also, various lightand plumbing fixtures, or any other accessories, may or may not bepresent. In embodiments, ceiling 102 may be manufactured and employed inthe manner described in connection with bathroom floor component 700. Aningress/egress area 180 may be provided.

Similarly, FIGS. 12 thru 15B depict the bathroom pod 100 as assembled.Some of the plumbing accessories are more easily seen including theshower accessories. Other features, configurations, and accessories arepossible in other embodiments of the present disclosure.

The ceiling 102 may be monolithic, crack-proof, and water proof. Theelectrical wiring 106 and the plumbing 108 may be pretested and codecompliant. The walls 104 may have moisture, mold and abuse resistantwallboard 107. Engineered steel framing studs 110 may hold the walls,and the bathroom floor component and the pod 100 as a whole, together.Accessories such as, but not limited to, a sink 115, rail 118, mirror111 and foot rest 113 may also be provided. One or more of thesefeatures or attributes may be omitted in other embodiments of thepresent disclosure.

Turning to FIGS. 16A and 16B, it can be understood that the bathroomfloor component 700 is assembled as a collection of component parts, and(as seen in connection with FIGS. 7-10 ) thereafter encapsulated withina one piece waterproof, rigid layer to result in a monolithic, extremelystrong floor member that resists bending, sagging and twisting. Thepre-encapsulated floor as shown may comprise any number of transversestrengthening members 702 and one or more of a plurality of peripheraloutside edge strengthening members 374. One or more foam floor-formingmembers 704 may be disposed between the one or more plurality oftransverse strengthening members 702 and peripheral strengtheningmembers 774. More particularly, at least one of the plurality of foamfloor members 704 may be disposed between an adjacent cross-bracestrengthening member 702 and an outside edge peripheral strengtheningmember 774. In some embodiments, a single peripheral strengtheningmember 774 and a single sheet of foam 704 may be employed, etc., to formthe bathroom floor component 700. The strengthening member(s) 702, 774may be bonded or otherwise attached to one or more of the foam floorpanels 704. Any suitable bonding agent may be used, such as glue, latexmodified rapid setting material, etc., as will occur to those of skillin the relevant art.

As best seen in FIGS. 16A-16B, one of the foam members 704 may define adrain aperture 378. The drain aperture 378, as well as any contour,e.g., slope or pitch to the upper surface of floor panels 704, may bemilled or drilled, etc. using a CNC (computer numerically controlled)router or milling machine, or other aperture-forming technique, etc., orformed using a molding process. In like manner, contour, e.g., supportribs (not shown), may be formed in the lower surface of floor members704. Later, a drain assembly 391 (such as the linear trench and lineardrain shown in the figures, or a circular drain, etc.) may be insertedinto the drain aperture 378 during the fabrication of the bathroom floorcomponent.

FIGS. 16A and 16B show floor component 700 prior to being encapsulatedwith a waterproof membrane 750. FIGS. 11, 12, 14, 15A and 15B show floorcomponent 700 after being encapsulated with a waterproof membrane 325.As can be seen, strengthening members 702 and 774, as well as theperipheral edges of drain fixture 391, can no longer be seen after floorcomponent 700 has been encapsulated.

Alternatively, as seen in FIG. 15C, the bathroom floor component and thesubstrate 785 may be mated together prior to applying the waterproofencapsulation layer, and then sprayed or otherwise coated with awaterproofing layer 325.

Bathroom Floor Components Including Underside Strengthening Members

FIGS. 18A-18F show a third embodiment of the invention along withvariations on the embodiment, in which a bathroom floor component isdisclosed comprised of one or more foam floor panels 904, optionally oneor more longitudinal strengthening members 902, and a peripheral raisedplatform defining a peripheral upper surface 977. One or more slopedfloor surfaces may be provided, as well as one or more drain apertures378 and one or more drain fixtures 391. Raised platform 976 may beattached or formed integrally with floor members 904, or connectedthereto using peripheral strengthening members (not shown) such asperipheral strengthening members 374 shown in FIGS. 15 and 16 . In theembodiment shown in FIGS. 18A-18F, strengthening members 374 are notemployed. However, it is to be understood that the use of suchstrengthening members may be included as being within the scope of theinvention.

The raised platform 976 is adapted to bear the weight of at least aportion of the walls 104 and ceiling 102 of pod 100, including theweight of any accessories attached thereto, and as such will beconstructed and arranged in such a manner that it can support saidweight without distortion (e.g., will resist collapse, crushing orbending). To that end, the material out of which peripheral shoulder 976is manufactured will be sufficient to support the weight of the ceiling102 and walls 104. Alternatively, strengthening inserts 979 and 989 maybe integrated into the peripheral raised platform 976 to addweight-bearing and anti-compressive capacity to the raised platformcomponent 976 of the bathroom floor component 900.

Additionally, the walls 104 of the bathroom pod 100 may connect theceiling to the bathroom floor component 900. The walls 104 may includebottom frame members 112 which are adapted to be placed in registry withupper surface 977. A plurality of hollow fastener-receiving bushings orjournals 116 may be disposed in the plurality of apertures 114 definedby raised platform 976. These bushings 116 may act as alignment featureswhen the walls are fastened to the bathroom floor component 900, act toprotect the integrity of apertures 114, which in some embodiments areformed in the polystyrene or other relatively soft foam making upsupport platform 976, and act to transfer weight from the walls 104 tothe sub-floor (not shown) supporting pod 100. In doing so, the raisedplatform 976 is protected from crushing. The hollow interiors ofbushings 116 allow fasteners 120 to extend through apertures 114 inraised platform 976 through the bottom wall of frame members 112.

Bushings 116 similar to those depicted in other embodiments herein, suchas metal cylindrical journals (not shown), which are preferablyfabricated of metal, although any material having good compressionresistance is suitable, may be used transfer weight from the walls 104down to the supporting surface or substrate (not shown) on which thebathroom floor component 900 will sit.

Alternatively or additionally, weight bearing supporting inserts such asintermediate inserts 979 and corner inserts 989 may be used to supportthe weight of walls 104 and ceiling 102. Fasteners may be used to attachthe walls 104 to the bathroom floor component 900 as described elsewherein this disclosure, using corresponding apertures 114 defined by supportinserts 979 and 989.

Support straps or bars 990 may be employed to transfer compressiveforces from walls 104 to tensile forces exerted within bars 990. Bars990 also serve to strengthen bathroom floor component 900, andultimately pod 100, against twisting, bending a sagging action.Preferably, bars 990 are recessed in corresponding slots 991 formed inthe lower surfaces of floor panels 904 and transverse strengtheningmembers 902 so as not to add any height dimension to the profile of thebathroom floor component 900. Bars 990 may be associated with bathroomfloor component 900 either before or after floor component 900 isencapsulated with waterproofing sealant 325. FIGS. 7D and 8D depictbathroom floor component 900 being coated with sealant 325 after bars990 have been associated therewith. It is to be understood that the stepof applying sealant 325 may be performed either before or after bars 990have been associated with floor 900.

In embodiments, bars 990 connect to walls 104 in the same manner asdescribed in connection with the interconnection of walls 104 withraised support platform 976.

Bathroom Floor Components with Reinforced Peripheral Support Platform

FIGS. 19-23 depict a further embodiment of the invention, wherein abathroom floor component 1000 includes one or more floor panels 1004L,1004R provided with a supporting and reinforcing frame 1050. The framemay be comprised of peripheral raised platform support members 1080, andmay also include, but not necessarily, longitudinal strengtheningmembers 1090. Support members 1080 are preferably attached tolongitudinal strengthening members 1090, as by welding, bolting or anyattachment means. Preferably, the frame members 1080, 1090 are made ofsteel, PVC, or the like, or other compression-resistant material. Thecross-sectional profile of the frame members may be any shape.

Preferably, as a seen in FIG. 20 , recesses 1086L and 1086R are providedin the underside of panels 1004L and 1004R to permit panels 1004L and1004R to nest within the peripheral support members 1080. Likewise,recesses 1092 may be provided in the underside of panels 1004L and 1004Rto permit longitudinal strengthening members 1090 to nest there within.In this way, the height of the bathroom floor component is kept to aminimum.

Floor panel 1004L may include sloped surfaces 1027, a flat surface 1025,and a drain, such as linear drain 378. Floor section 1004R defines anupper surface which may be flat, or maybe sloped as well.

Floor sections 1004L and 1004R define raised peripheral supportplatforms 1077L and 1077R adapted to be placed in registry with the podwalls when assembled with the pod. As seen in FIG. 22 , the raisedperipheral support platform is integrally formed with floor member 1004,which adds to the strength of the unitary member. Floor panels 1004,frame members 1080 and longitudinal strengthening members 1090 areencapsulated in a waterproof membrane prior to being connected with podwalls 104. Fastening means such as nut and bolt arrangements 120 may beused to connect bathroom floor component 1000 to pod walls 104. Anyother suitable fastening arrangement may be used. Once so connected,floor and wall tile 390, 394, respectively, may be applied tocosmetically finish off the pod. An ingress/egress area 180 may beprovided. It is to be understood throughout this disclosure that theframe and the floor panel(s) (and raised peripheral support platform ifused) may be encapsulated together within the waterproof membrane, orthe floor panel(s) itself (themselves) (and raised peripheral supportplatform if used) may be encapsulated within the waterproof membraneand, thereafter, the frame associated therewith, such that the frame andfloor panel(s) is (are) not integrated within the waterproof membranetogether.

In embodiments, the raised peripheral support platform 1076 may be aswide as only the wall 104 and/or wall studs 110, or may be wide enoughto reside in registry with the wall board 107 as well, as seen in FIGS.22-23 . The raised peripheral support platform 1076 also may be wider ornarrower than the wall studs with or without wall board attached.

In the case where the floor member is made up of two panels 1004L and1004R, those panels are joined together at opposed edges 1020L, 1020R,as best seen in FIG. 21 . In embodiments, floor panel 1004 is a singlepiece of foam or plastic (or any other suitable material) that spans theentirety of the frame 1050. In other embodiments, such as that shown inFIGS. 22B and 23B, the floor panel is made up of two or more members. Inany embodiment, floor panels may be stacked on top of each other tocreate a thicker floor, and may be machined in areas to create contour(e.g., slope or drain cutouts).

In embodiments, as shown in FIGS. 24-28 , the floor member may be madefrom a single, unitary floor panel 1004 defining peripheral raisedsupport platform 1096, instead of separate panels 1004L and 1004R orhowever many panels may be necessary to cover a given floor area. In thecase of larger floor areas, it may be desirable or efficient to utilizemore than one floor panel member with frame 1050, or it may be desirableor efficient to use just a single floor panel such as panel 1004. Inaddition or alternatively, it may be desirable or efficient to use areinforcing frame arrangement that is made of larger or smallercomponent parts than those shown in the drawings. It is also importantto note that the height of any raised peripheral support platformdisclosed herein in connection with any embodiment can be specifiedaccording to the designer or customer to be whatever height desired fora particular application.

Numerous floor features such as sloped bathroom floor upper surfaces1004A and 1004C, as well as flat bathroom floor area 1048B, shown inFIG. 24 , may be employed as will occur to those of skill in the art. Inaddition, in any of the embodiments described in this disclosure,additional or alternative features such as the following may beincluded:

-   -   a. An additional drain or drains may be included in a non-shower        area of the bathroom floor member;    -   b. a second shower may be provided in the bathroom pod;    -   c. a non-shower pitched wet area may be provided in the bathroom        pod;    -   d. a flat bathroom floor area may be provided in the bathroom        pod;    -   e. non-shower dry pitched bathroom floor area may be provided in        the bathroom pod; and/or    -   f. a shower bench may be provided in the bathroom pod.

Preferably, as a seen in FIG. 25 , recesses 1086 are provided in theunderside of panel 1004 to permit panel 1004 to nest within theperipheral support members 1080. Likewise, recesses 1092 may be providedin the underside of panel 1004 to permit longitudinal strengtheningmembers 1092 to nest there within. In this way, the height of thebathroom floor component is kept to a minimum.

Floor panel 1004 may include optional features such as sloped surfaces1027, a flat surface 1025, and a drain, such as linear drain 378.

Floor panel 1004 defines raised peripheral support platform 1077 adaptedto be placed in registry with the pod walls when assembled with the pod.As seen in FIG. 27 , the raised peripheral support platform isintegrally formed with floor member 1004, which adds to the strength ofthe unitary member. Floor panels 1004, frame members 1080 andlongitudinal strengthening members 1090 may be encapsulated in awaterproof membrane prior to being connected with pod walls 104.Fastening means such as nut and bolt arrangements 120 may be used toconnect bathroom floor component 1000 to pod walls 104. Any othersuitable fastening arrangement may be used. Once so connected, floor andwall tile 390, 394, respectively, may be applied to cosmetically finishoff the pod.

In embodiments, the raised peripheral support platform 1076 may be aswide as only the wall 104 and/or wall studs 110, or may be wide enoughto reside in registry with the wall board 107 as well, as seen in FIGS.22-23 , and can be narrower or wider than the u-channels which underlythe wall studs 110 with or without the wall board.

In any embodiment, the floor panel(s) 1004 may be comprised of two ormore thinner panels stacked on top of each other to create a desiredfloor thickness, and may be machined in areas to create contour (e.g.,slope or drain cutouts). In this way, panels that are manufactured to bethinner than the greatest thickness that will be needed for the floormember can be stacked together as shown in FIGS. 22B and 23B, as well as27B and 28B, because individual, thinner, floor panels can bemanufactured faster and cure faster. The individual panels 1004 can besecured together by adhesive (or simply stacked on top of each otherwithout adhesive), and the top panel (or however many panels are used)can be milled to create contour in the floor member, as well asapertured for one or more drains or any other purpose.

Bathroom Floor Member with Splashwalls and Support Frame

FIGS. 27-35 depict another embodiment of the invention, wherein abathroom floor component is comprised of a shower member 1100 associatedwith a support substrate 1150.

Floor member 1100 preferably includes recessed grooves 1192 into whichsupport frame members 1180, 1190 nestably relate. Floor member 1100 mayalso include raised splash walls 1115 around the perimeter thereof otherthan at the entry or entries to the bathroom. Floor member 1100 alsodefines an upper floor surface, at least a portion of which taperstoward a drain opening 378. A suitable drain insert, such as draininsert 391, may be employed. As will occur to those of skilled in theart, any type of drain may be used in any of the applications of theinvention disclosed herein.

In one version of this embodiment, as best seen and FIG. 32A, the floormember is encapsulated with a waterproofing layer 325 and connected tothe support frame 1150, which in turn is connected to pod walls 104,after which finishing material such as wall and floor tile 390, 394 maybe attached.

In another version of this embodiment, as shown in FIG. 32B, showerfloor member 1100 and support frame 1150 are both encapsulated withwaterproofing material layer 325, and thereafter attached to pod walls104. Thereafter, finishing materials may be applied there too, such asfloor and wall tile 394, 390.

FIG. 33 is a top perspective view of the shower floor member 1100 ofthis embodiment. FIG. 34 is the same view as in FIG. 33 , but afterwaterproofing layer 325 has been applied thereto. FIG. 35 is a bottomperspective view thereof after the waterproofing layer 325 has beenapplied.

Closed Cell Single Panel Material for Floor Panels, for Raised Platformand/or for Both.

In embodiments, such as shown in FIGS. 4C and 5C, 8D and E, 11-17B,18A-18I, and 27-35, the floor member of the bathroom floor component maybe comprised of a one-piece floor panel manufactured of a waterimpervious material. In such cases, the waterproof membrane discussedelsewhere in this disclosure may be unnecessary. In other embodiments,the floor panel may be manufactured of a water impervious material butany raised platform may be made of one or more different materials(including anti-compression elements), and vice versa.

Moreover, in any of the disclosed embodiments, one or more of theadditional or alternative features such as the following may be includedin the bathroom floor component:

-   -   a. one or more additional drains (not shown) may be included in        a non-shower area of the bathroom floor member;    -   b. one or more additional showers (not shown) may be provided in        the bathroom pod;    -   c. one or more non-shower pitched wet areas (such as the        intermediate areas 904 in FIGS. 18A and E) may be provided in        the bathroom floor component, which is/are designed to become        wet and drain water therefrom toward a provided drain;    -   d. one or more flat bathroom floor areas (such as the area 904        to the far right in FIGS. 18A and E) may be provided anywhere in        the bathroom floor component, defined by the floor member;    -   e. one or more non-shower dry pitched/sloped bathroom floor        areas (not shown) may be provided in the bathroom floor        component, defined by the floor member; and/or    -   f. one or more shower benches (not shown) may be provided in the        bathroom pod upon which a user may sit, rest a foot, etc.

Strengthening Members.

Strengthening members such as those described throughout thisdisclosure, including the anti-compressive members, provide support andrigidity for the bathroom floor components. Certain strengtheningmembers are focused exclusively on strengthening the bathroom floorfeature of a bathroom floor component. Other strengthening members arefocused exclusively on strengthening the raised platform feature of thebathroom floor component. A third category of strengthening members arefocused on strengthening both the bathroom floor feature and the raisedplatform feature of the bathroom floor component.

Strengthening members can comprise any type of material, including butnot limited to wood, metal, plastic, concrete, stone, polyurethane,along with any and all other types of structures or apparatus that wouldbe adequate for peripheral or transverse strengthening purposes. Thesematerials may be used individually and in combination with othermaterials depending upon the specific support requirements of a specificbathroom floor feature and a specific raised platform feature of aspecific bathroom floor component.

For the bathroom floor component strengthening members, their supportcharacteristics are specific to where they are located in the bathroomfloor component.

For all embodiments, the heads of fasteners 120 are preferably recessedinto the respective apertures 114, particularly at the bottom of raisedplatforms 376, 776 and 976, so as not to unnecessarily add to the heightof the bathroom floor component. Appropriate weight-dispersing featuressuch as washers and/or bushings 116 may be employed to distribute forcesto the extent necessary to avoid cracking or other disturbance in thewaterproof layer 325 or any other aspect of the bathroom floorcomponent.

The top surfaces 377, 1077 of the raised support platforms in allembodiments are preferably horizontal. Fasteners and fastener-receivingstructures are preferably recessed in the raised platform to maintain auniformly flat and thin profile.

It is understood that the raised platform is not needed where there is athreshold into the bathroom, such as in the doorways shown in FIGS. 1,2A, 11 and 12 . In embodiments, therefore, the raised platform isprovided only where pod walls 104 are provided. In this way, ingress andegress to the bathroom will be unimpeded by the peripheral supportplatforms 376, 976 and 1076. Also, as stated previously, it is importantto note that the height of any raised peripheral support platformdisclosed herein in connection with any embodiment can be specifiedaccording to the designer or customer to be whatever height desired fora particular application.

Frame member 1050 acts as a strengthening member for both the floor andthe raised platform, along with providing strengthening to any othermember with which it is associated. In this, resistance to bending,twisting and sagging is provided.

It is also to be understood that bathroom pods manufactured inaccordance with the description set forth herein are typically set uponsubstrates, in many cases concrete slabs, in buildings underconstruction. It is desired to avoid changes in height when going fromthe substrate/floor of the building into the prefabricated bathroom pod(for example, at an entrance area 180 of any of the floor membersdescribed herein) to avoid tripping and/or to meet various disabilitycodes. In some cases, recesses are provided in such building floorsubstrates to accommodate the depth necessary for sloped shower floors.The bathroom floors of the present invention, containing one or moredrains, in most cases employ floors which slope toward such drain(s).The slope of the floors requires the bottom surfaces of the bathroomfloor components disclosed herein to have a certain clearance depthaccommodated by the substrate, which in appropriate cases isaccomplished by creating a recess in the upper surface of the substrate.Preferably, selecting combined dimensions of the thickness of the floormember of the bathroom floor components, and the depth of any recess(es)in the building floor substrate which the bathroom floor member sits in,results in the upper surface of the finished floor of the bathroom floorcomponent immediately adjacent the bathroom pod entrance being atsubstantially the same height as the finished floor of the building intowhich the bathroom pod is being installed immediately adjacent thebathroom pod entrance. Alternatively, the height of the unfinished floorat the bathroom pod entrance may be engineered to be at substantiallythe same height as the adjacent room.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the embodiments of theapparatus and methods of assembly as discussed herein without departingfrom the scope or spirit of the invention(s). Other embodiments of thisdisclosure will be apparent to those skilled in the art fromconsideration of the specification and practice of the variousembodiments disclosed herein. For example, some of the equipment may beconstructed and function differently than what has been described hereinand certain steps of any method may be omitted, performed in an orderthat is different than what has been specifically mentioned or in somecases performed simultaneously or in sub-steps. Furthermore, variationsor modifications to certain aspects or features of various embodimentsmay be made to create further embodiments and features and aspects ofvarious embodiments may be added to or substituted for other features oraspects of other embodiments in order to provide still furtherembodiments.

Accordingly, it is intended that the specification and examples beconsidered as exemplary only, with a true scope and spirit of theinvention(s) being indicated by the following claims and theirequivalents.

What is claimed is:
 1. In a prefabricated bathroom pod adapted to beplaced on a floor substrate in a building, the bathroom pod comprising aceiling, a plurality of walls, electrical wiring and plumbingaccessories, an improvement comprising: a bathroom floor componentincluding a floor member, the bathroom floor component supported by asupport substrate, wherein the walls connect the ceiling to the supportsubstrate.
 2. The bathroom floor component of claim 1, furthercomprising at least one elongated floor strengthening member attached tothe floor member.
 3. The bathroom floor component of claim 2, whereinthe floor member is comprised of two or more floor panels attached toeach other via at least one of the elongated floor strengtheningmembers.
 4. The bathroom floor component of claim 1, further comprisinga support frame connected to the floor member.
 5. The bathroom floorcomponent of claim 4, wherein the floor member is comprised of two ormore floor panels.
 6. The bathroom floor component of claim 1, whereinthe floor member defines an upper surface and a drain opening, and atleast a portion of the upper surface being sloped toward the drainopening.
 7. The bathroom floor component of claim 5, wherein the floormember defines an upper surface and a drain opening, and at least aportion of the upper surface being sloped toward the drain opening. 8.The bathroom floor component of claim 3, further comprising aperturesdefined by the support substrate adapted to receive fasteners to connectthe bathroom floor component to the walls.
 9. The bathroom floorcomponent of claim 4, further comprising recesses in a bottom surface ofthe floor member to receive the support frame in nested relation. 10.The bathroom floor component of claim 1, wherein the support substratedefines an outer peripheral flange having a width substantially the sameas a width of the pod walls.
 11. The bathroom floor component of claim1, wherein the pod walls include wall board members connected thereto,and wherein the support substrate defines an outer peripheral flangehaving a width substantially the same as a width of the pod walls plusthe thickness of the wall board.
 12. The bathroom floor component ofclaim 10, further comprising splashwalls connected to peripheral edgesof the floor member.
 13. The bathroom floor component of claim 1,wherein the floor member is polyethylene or polyethylene foam.
 14. Thebathroom floor component of claim 12, wherein the splashwalls arepolyethylene or polyethylene foam.
 15. The bathroom floor component ofclaim 1, wherein the floor member is polyurethane or polyurethane foam.16. The bathroom floor component of claim 12, wherein the splashwallsare polyurethane or polyurethane foam.
 17. The bathroom floor componentof claim 1, wherein the floor member includes an entrance area toprovide ingress into and egress out of the bathroom pod, and wherein anupper surface of the floor member at the entrance area is substantiallycoplanar with an upper surface of the floor substrate of the building.18. In a premanufactured bathroom pod adapted to be placed on a floorsubstrate in a building, the bathroom pod having a ceiling and aplurality of walls, a reinforced floor system comprising: a floor memberdefining a first drain opening and an upper surface, at least a portionof the upper surface being sloped toward the drain opening; a waterproofmembrane surrounding the floor member; and a support substrate defininga peripheral flange adapted to reside in registry with bottom edges ofthe walls.
 19. The floor system of claim 18, wherein the floor member iscomprised of two or more floor panels.
 20. The floor system of claim 18,further comprising: a plurality of spaced apertures defined by saidperipheral flange adapted to receive fasteners therethrough to attachthe floor system to the walls.
 21. The floor system of claim 20, whereinthe floor member is comprised of two or more floor panels.
 22. The floorsystem of claim 21, further comprising longitudinal strengtheningmembers between and interconnecting the two or more floor panels. 23.The floor system of claim 18, wherein the floor member is comprised of afirst, upper, floor panel and a second, lower, floor panel, the slope inthe floor member being defined by an upper surface of the upper floorpanel, the recesses being defined by a bottom surface of the lower floorpanel.
 24. The floor system of claim 18, further comprising compressionresisting members integrated into the peripheral flange adapted totransfer weight from said walls.
 25. The floor system of claim 24,wherein the compression resisting members are metal bushings situated insaid apertures, and further wherein the bushings are hollow and adaptedto receive said fasteners.
 26. The floor system of claim 24, wherein thecompression resisting members comprise a plurality of spaced apartblocks of material that have higher compression resistance than theperipheral flange.
 27. The floor system of claim 18, wherein the floormember is polyurethane or polyurethane foam.
 28. The floor system ofclaim 18, wherein the slope of the floor member is created by CNCmilling.
 29. The bathroom floor component of claim 18, wherein the floormember includes an entrance area to provide ingress into and egress outof the bathroom pod, and wherein an upper surface of the floor member atthe entrance area is substantially coplanar with an upper surface of thefloor substrate of the building.
 30. The bathroom floor component ofclaim 24, wherein the floor member includes an entrance area to provideingress into and egress out of the bathroom pod, and wherein an uppersurface of the floor member at the entrance area is substantiallycoplanar with an upper surface of the floor substrate of the building.31. The bathroom floor component of claim 18, further comprising one ormore additional drain openings defined by a non-shower area of the floormember.
 32. The bathroom floor component of claim 18, further comprisingone or more additional showers provided in the bathroom pod.
 33. Thebathroom floor component of claim 18, wherein the floor member definesone or more non-shower sloped areas which are adapted to receive anddrain water.
 34. The bathroom floor component of claim 18, furthercomprising one or more non-sloped floor areas defined by the floormember.
 35. The bathroom floor component of claim 18, wherein the floormember defines one or more non-shower sloped areas.
 36. The bathroomfloor component of claim 18, further comprising one or more showerbenches associated with the bathroom pod.
 37. In a prefabricatedbathroom pod comprising a ceiling, a plurality of walls, electricalwiring and plumbing accessories, an improvement comprising: a pluralityof peripheral strengthening members; a plurality of longitudinalstrengthening members; a plurality of plastic or foam floor members; andwherein the plurality of peripheral strengthening members are joined tothe plurality of longitudinal strengthening members, defining aplurality pockets, and at least one of the plurality of floor members isdisposed in each of the plurality of pockets.